Engineered waterproof plastic composite flooring and wall covering planks

ABSTRACT

Waterproof engineered floor and wall planks have a veneer layer bonded with a plastic composite core, and an underlayer, preferably an underlayer of cork.

CLAIM OF PRIORITY

The present application is a continuation of and also claims priority toU.S. patent application Ser. No. 16/037,939, filed on Jul. 17, 2018,which is a continuation of application Ser. No. 14/980,235, filed onDec. 28, 2015, now U.S. Pat. No. 10,024,066 issued Jul. 17, 2018, whichis a continuation of U.S. patent application Ser. No. 14/816,181, filedAug. 3, 2015, now U.S. Pat. No. 9,234,357 issued Jan. 12, 2016, which isa continuation of U.S. patent application Ser. No. 13/657,750, filedOct. 22, 2012, now U.S. Pat. No. 9,156,233 issued Oct. 13, 2015.

FIELD OF THE INVENTION

This invention relates to flooring, and particularly a new and improvedwaterproof flooring utilizing bamboo and plastic.

BACKGROUND OF THE INVENTION

In the flooring industry, there is a significant need for waterproofflooring that presents the appearance of a wooden floor. In particular,this flooring needs to be not only resistant to moisture, but alsoeconomical, easy to install, easy to maintain, and comfortable to walkon.

In the flooring industry, laminate flooring using fiberboard or particleboard as the core layer has gained a tremendous market share. Suchlaminate flooring is manufactured with numerous desirable propertiessuch as reasonable cost, stain resistance, wear resistance, easymaintenance, and fire resistance. In addition, laminate flooring is ableto carry many types of printed designs, including wood grain designs.

Natural wood floors, particularly of oak and other hardwoods have beenemployed as flooring materials for centuries. While not as economical aslaminate flooring, the appearance and comfort of wooden flooring ishighly desirable. One of the most significant drawbacks to both laminateand wooden flooring is their performance when subjected to sustainedexposure to moisture. In the case of wooden floors, moisture will causeswelling and warping of the flooring leading to an uneven surface andeven gaps between the planks. In the case of laminate flooring,sustained exposure to moisture will frequently destabilize the integrityof the fiberboard or particle board material causing permanent andirreparable damage to the laminate boards. This leads many flooringinstallers to avoid the use of laminate flooring in areas that aresubject to repeated or sustained moisture such as in the kitchen,bathroom, laundry room and basement areas of a house or in thecommercial settings of restaurants and some retail stores.

As a result of the shortcomings of wood and laminate flooring, thechoices for flooring in wet areas have traditionally been limited toceramic tile, stone, and rubber or vinyl flooring. With ceramic tile andstone, the visual choices are limited, the cost of materials andinstallation is relatively high, and the resulting floors are cold inthe absence of subsurface radiant heating and hard to stand on forextended periods of time. Rubber and vinyl floors can be relativelyinexpensive, however, because these flooring materials are not rigid,imperfections from the subfloor transfers through the rubber or vinyland appears on the floor surface which can be aesthetically jarring. Inaddition, the strength of adhesives used with rubber and vinyl floorscan be compromised by moisture that can result in curling damage sincethe floors lack rigidity.

To address these issues, laminate flooring has been manufactured withimproved moisture resistance through the selection of melamine,isocyanate or phenolic binders and through application of waterproofingmaterials and silicone caulking to seal voids. These steps remaininadequate however, both due to added time of installation and cost ofmanufacture, and because these waterproofing attempts are not 100%effective. One attempt to produce a suitable laminate plank is describedin U.S. Pat. No. 7,763,345, and its related applications, where athermoplastic material core is created and a print layer and aprotective overlay are applied to the top side. The thermoplasticmaterial core is typically a rigid polyvinylchloride compound and thecore is extruded with cavities to provide cushioning. Extruded plankshave a tendency to cup, however, and even with cavities, the PVCthermoplastic core is not inexpensive.

In modern construction it is also desirable to utilize green or recycledmaterials to minimize the environmental cost of construction. As aresult, it is desirable to maximize the use of recycled or wastematerials whenever possible. Therefore, a need exists for improvedwaterproof engineered flooring and wall covering material.

SUMMARY OF THE INVENTION

A feature of the present invention is to provide a rigid waterproofflooring or wall covering plank that includes the possibility of a widevariety of visual surface appearances, a rigid and relativelyenvironmentally friendly core, and an optional cushioned backing. Theengineered planks according to the invention may advantageously utilizea locking system so that the flooring can be snapped together as afloating floor, employing the floating floor installation method whereno adhesive is required to bond the flooring planks to the subfloor. Inaddition, a portion of the engineered waterproof plank materials cancomprise bamboo dust, wood dust or cork dust that is substantially abyproduct of other flooring manufacturing processes.

By combining the bamboo, wood or cork dust, or combination thereof, withhigh density polyethylene (HDPE), or polyvinylchloride (virgin,recycled, or a mixture thereof), a rigid and inert core is provided thatdoes not absorb moisture and does not expand or contract, therebyeliminating the formation of peaks and gaps.

BRIEF DESCRIPTION OF THE DRAWINGS

The particular features and advantages of the invention as well as otherobjects will become apparent from the following description taken inconnection with the accompanying drawings in which:

FIG. 1 is a perspective view of an exemplary engineered waterproofflooring plank according to the invention.

FIG. 2 is an exploded sectional view of an exemplary flooring plankaccording to the invention.

FIGS. 3a-d depict exemplary prior art click-lock edge configurationsthat may be advantageously used with various planks made according tothe invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

In general, the present invention relates to a waterproof engineeredflooring plank or wall panel. The end view of the exemplary flooringplank 10 shown in FIG. 1 shows the three principal structural componentsof the plank. Specifically, the top surface is a veneer layer, such aswear layer 20, that is waterproof and is selected from a number ofpossible materials including: tile or stone veneers; rubber; decorativeplastic; decorative vinyl; linoleum; and any material (such as cork,bamboo or wood veneer) encapsulated in vinyl or resin to render thelayer waterproof and wear resistant. A decorative vinyl wear layer isparticularly cost and performance effective. This surface is not onlyresistant to moisture, but can also be provided with a staticcoefficient of friction (CoF) of about 0.68 according to ASTM C 1028-96,and a CoF of at least about 0.60 is desirable for most applications.

The middle section or core 30 of the engineered plank 10 is a compositematerial formed from raw or unprocessed bamboo dust, wood dust, corkdust or a mixture thereof and high density polyethylene (HDPE) oralternatively, virgin or recycled PVC or a combination of such PVCs, andup to about 10% chemical additives such as anti-UV agents,anti-oxidation agents, stabilizers, colorants, anti-fungus agents,coupling agents, reinforcing agents, and lubricants. Calcium carbonatemay also be added as a filler. After blending and melting the dust andHDPE or PVC, and additives and filler, the composite material isextruded to desired dimension. This type of HDPE and dust composite haspreviously been manufactured primarily for use as outdoor decks,railings and fences, but heretofore has not been used in a fashion thatwas sufficiently visually appealing or commercially viable forresidential or commercial flooring. Instead, these wood-plastic orbamboo-plastic composites have been impregnated with colors according toa limited color pallet suitable and only promoted for exterior use. Whenused in the present invention, some additives, such as anti-UV agents,anti-fungals, and insecticides, are not needed. Also, heretofore, corkdust has not been a principal ingredient of the plastic composites.Whereas generally the addition of greater amounts of wood or bamboo dustprovided greater rigidity to the resulting planks, cork dust retainssome resilience even in the plastic mixture. The core 30 can be solid,or can be provided with channels or cavities if desired, particularly inrelatively thick embodiments.

The underlayment layer 40 is attached to the extruded dust and plasticcore 30 and is also made of waterproof or water resistant material suchas cork, rubber, foam or waterproof balancing paper.

The plank 10 also has a grooved end 50 with profile 51 and channel 52that matches with protruding end 60 having profile 61 and protrusion 62.The particular profiles are made according to a preferred design toallow the panels to be quickly locked together, typically without theuse of adhesive. However, if desired, an adhesive may be applied to theprofiles therefore joining planks together to create a more permanentbonding of adjacent planks. The matching profiles may be of theclick-lock variety depicted in FIGS. 3a-d or a more traditional tongueand groove construction that generally requires the use of an adhesive.

FIG. 2 is an exploded view of the various layers that may be included ina plank or wall panel of the invention. The top layer 21 is an optionalprotective overlay or cover layer that is most desirable when the wearlayer 20 is not particularly durable. Preferred top layercharacteristics include transparency, hardness and scratch resistance.Exemplary materials for a top layer 21 include melamine resin withaluminum oxide and polyurethane. Wear layer 20 is less likely to benefitfrom a top layer 21 when comprised of a durable material such as tile orstone, or when the wear layer 20 already includes a protective hardenersuch as is the case with resin or vinyl encapsulated bamboo, wood orcork.

A bonding layer 22 joins the wear layer 20 to the core 30 and istypically, though not exclusively, a water resistant adhesive. Apreferred adhesive type is a hot melt adhesive that can be appliedduring the manufacture of the engineered flooring or wall covering, attemperatures over 200° F., and more commonly over 250° F., and istherefore not suitable for convenient use at a residence or commercialestablishment when flooring is being installed. The hot melt adhesiveshould be water resistant or nearly impervious to significant andprolonged exposure to moisture.

Another bonding layer 41 joins the underlayment layer 40 to the core 30.As with the first bonding layer 22, this second bonding layer 41 is alsopreferably a hot melt adhesive that is nearly impervious to moisture.The underlayment layer 40 is selected from a variety of possiblematerials depending upon the price point and functionality of theflooring or wall covering planks.

Planks according to the present invention are advantageously providedwith click-lock edge systems, such as the protrusion 62 that co-operateswith channel 52 and edge profiles 51, 61. Pervan, U.S. Pat. No.6,023,907 and Morian, U.S. Pat. No. 6,006,486 disclose two of theleading edge fastening systems. FIGS. 3a-d show a variety of otherclick-lock edges. The system in FIG. 3a can be angled and snapped, FIG.3b shows a snap joint, FIG. 3c can be angled and snapped but generallyhas less joining strength than the system of FIG. 3a . FIG. 3d alsoshows lock and fold panels with the first panel having a channel on theright edge being installed and the second panel being angled so that itsprotrusion enters the channel and the top edges of the two panelscontact, and then rotating the second panel downward until the profilesare locked. When using click-lock edges, it is relativelystraightforward to install floating flooring without adhesives. Theparticular edge system that is preferred for a particular plank may varydepending upon the dimensions and rigidity of the plank. It will also beunderstood that planks and panels according to the present invention canbe installed using adhesives, and the adhesives can be applied to jointhe edges of the planks or to attach the planks to the subfloor or wall,or both.

The planks and panels according to the invention are generallyrectangular having a thickness of up to about one inch (about 25.4 mm)and a width of between about 2 and 12 inches (about 50 mm to about 305mm). In general, flooring planks will have a greater thickness than wallcovering planks or panels. The use of recycled wood, cork or bamboo dustcontributes to sustainability through the responsible management ofresources, and provided bamboo, cork or sustainably harvested wood isused, results in an environmentally friendly building material.

The planks and panels manufactured according to the invention are nearlyimpervious to swelling and have great dimensional stability. Theseplanks and panels exhibit variations due to moisture of less than 0.01%.The products can also be manufactured to tolerances of less than 0.25 mmof length, width and straightness, and many suitable wear layers providecolorfast and cleanable surfaces.

Numerous alterations of the structure herein disclosed will suggestthemselves to those skilled in the art. However, it is to be understoodthat the present disclosure relates to the preferred embodiment of theinvention which is for purposes of illustration only and not to beconstrued as a limitation of the invention. All such modifications whichdo not depart from the spirit of the invention are intended to beincluded within the scope of the appended claims.

We claim:
 1. An engineered waterproof plank comprising: (a) a veneer layer adhered to a top surface of a rigid waterproof core, wherein the veneer layer is selected from a group consisting of wood veneer, cork veneer, bamboo veneer, tile veneer, stone veneer, rubber veneer, decorative plastic veneer, linoleum veneer and decorative vinyl veneer; (b) a waterproof adhesive layer bonding the veneer layer to the top surface of the rigid waterproof core; (c) the rigid waterproof core comprising a plastic composite; (d) the engineered waterproof plank having a first edge with a groove extending laterally into the rigid waterproof core and a second opposite edge with a tongue extending from the rigid waterproof core; wherein the plastic composite further comprises a plastic and an additive, said additive selected from a group consisting of anti-UV agents, anti-oxidation agents, stabilizers, colorants, anti-fungus agents, coupling agents, reinforcing agents, and lubricants.
 2. The engineered waterproof plank of claim 1, wherein the plastic composite comprises an extruded plastic composite.
 3. The engineered waterproof plank of claim 1, wherein said plastic composite further comprises a plastic selected from a group consisting of high-density polyethylene and polyvinyl chlorides.
 4. The engineered waterproof plank of claim 1, wherein the plastic composite further comprises: (a) 20% to 45% of a plastic selected from a group consisting of high-density polyethylene and polyvinyl chlorides, and (b) a filler.
 5. The engineered waterproof plank of claim 4, wherein the filler comprises calcium carbonate.
 6. The engineered waterproof plank of claim 1 wherein the veneer layer is encapsulated in one of resin and vinyl to render the veneer layer waterproof and wear resistant.
 7. An engineered plank comprising: a waterproof rigid core comprising a plastic composite, wherein said plastic composite further comprises a plastic and a filler, and wherein said filler is calcium carbonate; a veneer layer disposed on a top surface of the waterproof rigid core, wherein the veneer layer is selected from a group consisting of wood veneer, cork veneer, bamboo veneer, tile veneer, stone veneer, rubber veneer, decorative plastic veneer, linoleum veneer and decorative vinyl veneer, and wherein the veneer layer is bonded to the top surface of the waterproof rigid core via a waterproof bonding; and a protective cover Dryer disposed above the veneer layer, the protective cover layer comprising one of a melamine based layer, an aluminum-oxide-based layer, and a polyurethane-based layer.
 8. The engineered plank of claim 7 wherein the plastic composite further comprises an additive selected from a group consisting of anti-UV agents, anti-oxidation agents, stabilizers, colorants, anti-fungus agents, coupling agents, reinforcing agents, and lubricants.
 9. The engineered plank of claim 7, wherein the plastic is selected from a group consisting of high-density polyethylene and polyvinyl chlorides.
 10. The engineered plank of claim 7, wherein the plastic composite comprises: (a) 20% to 45% of the plastic selected from a group consisting of high-density polyethylene and polyvinyl chlorides, and (b) the filler.
 11. The engineered plank of claim 7, wherein exposure to moisture results in swelling of plank dimensions by less than 0.01%.
 12. The engineered plank of claim 7, wherein the engineered plank comprises one of a floor plank and a wall plank.
 13. The engineered plank of claim 7, further comprising a first edge with a groove extending laterally into the waterproof rigid core and a second opposite edge with a tongue extending from the waterproof rigid core.
 14. An engineered plank comprising: a rigid inert core that is at least one of waterproof and water-resistant, wherein said rigid inert core comprises a plastic composite, wherein said plastic composite further comprises a plastic and a filler, and wherein said filler is calcium carbonate; a veneer layer disposed on a top surface of the rigid inert core, wherein the veneer layer is selected from a group consisting of wood veneer, cork veneer, bamboo veneer, tile veneer, stone veneer, rubber veneer, decorative plastic veneer, linoleum veneer and decorative vinyl veneer, and wherein the veneer layer is bonded to the top surface of the rigid inert core via a waterproof bonding; a protective cover layer disposed above the veneer layer, the protective cover layer comprising one of a melamine based layer, an aluminum oxide based layer; and a polyurethane based layer; and the plank having a first edge with a groove extending laterally into the rigid inert core and a second opposite edge with a tongue extending from the rigid inert core.
 15. The engineered plank of claim 14, wherein the waterproof bonding comprises a water-resistant adhesive.
 16. The engineered plank of claim 14, wherein the plastic is selected from a group consisting of high-density polyethylene and polyvinyl chlorides.
 17. The engineered plank of claim 14, wherein the plastic composite comprises: (a) 20% to 45% of the plastic selected from a group consisting of high-density polyethylene and polyvinyl chlorides; and (b) the filler.
 18. The engineered plank of claim 14, wherein the engineered plank comprises one of a floor plank and a wall plank.
 19. The engineered plank of claim 14, further comprising an underlayer, said underlayer selected from a group consisting of cork, rubber, foam, and waterproof balance paper, wherein a waterproof adhesive layer bonds the underlayer to a bottom surface of the rigid inert core. 